Deploying 3D Concrete Printing for Large-Scale Building Construction in Saudi Arabia (2025-10)¶

This paper details the successful large-scale implementation of 3D concrete printing (3DCP) for the construction of large building in remote area of Saudi Arabia. As one of the first religious buildings in the region constructed using additive manufacturing, this project showcases 3DCP's technological and environmental potential for contemporary building. In order to ensure sustainability and cost effectiveness, the mosque was constructed using a COBOD BOD2 gantry printer and a customised concrete mix made up of 99% locally sourced materials and 1% CEMEX D-fab admixture. To maximise thermal insulation and accommodate mechanical, electrical, and plumbing (MEP) systems, the structure included a dual-layer wall system with two outer layers that were each 5 cm thick and separated by a 10 cm cavity. In comparison to traditional methods, the project achieved impressive metrics, such as a 30% increase in energy efficiency, a 50% reduction in construction time, and an 80% labor savings. The printer reached a maximum build height of 5.54 meters while operating at a production rate of 350 linear meters per hour. With its ability to withstand thermal stress, chloride ion penetration, and cracking in extreme weather conditions, the concrete mix showed exceptional durability. With an overall average compressive strength of 33.52 MPa, which is higher than the design strength of 30 MPa, compressive strength tests produced consistent average results across all phases. Through creative reinforcement techniques, accurate automated layer calibration, and environmentally friendly building methods, this case study demonstrates the scalability and adaptability of 3DCP in harsh climates. Significant accomplishments include a 40–50% decrease in carbon emissions and an 85% reduction in material waste, with effective waste as low as 2-4 percent. The findings support 3DCP as a groundbreaking approach to durable, effective, and ecologically friendly building, providing a replicable framework for approaching public, industrial, and residential developments worldwide.